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DOE OSTI2024

On-PIC Light Source Integration & Micro-dispensing of Solder Paste for Flip Chip Application

To reach the next level benefits of photonic integrated circuits (PICs), the Integrated Photonic Systems Roadmap-International describes the necessity of either heterogeneous or hybrid integration of light sources [1]. A new approach for hybrid integration is Photonic Wire Bonding where 3D nanolithography is used to pattern a polymer waveguide that connects light sources to PIC waveguides. The waveguides resemble electrical wire bonds and essentially do the same as their electrical counterpart for packaging photonic chips together. In order to reap the full benefits of a photonic wire bonds, the light source must be carefully packaged. In this work I seek to expand RIT’s photonic packaging capability by establishing a packaging process to integrate light sources, specifically an Indium Phosphide distributed feedback lasers and a reflective semiconductor optical amplifiers, directly onto a photonic integrated circuits. Another necessary requirement for PIC packaging is densely integrated electrical connectivity. In this thesis I developed a fine pitch flip chip interconnect technique demonstrated using gold stud bumps in conjunction with micro-dispensed solder paste. This work opens the door to high density photonic flip chip applications. The micro-dispensed solder paste dots having diameters 50-125 µm are currently being tested at a pitch of 150 µm . The gold stud bumps are formed with 1mil gold wire creating bumps with a diameter of 40-60 µm depending on specific parameter values. These capabilities will allow RIT to assemble and test novel photonic integrated devices, cutting down on the time and cost associated with third party assembly and tests facilities. Thereby keeping RIT at the forefront of photonic research.

Wongk, Nicole↗

NASA NTRSDate not supplied

Gateway Induced Environments Overview

Gateway will be a long duration space station orbiting the Moon in support of NASA’s Artemis campaign. Over its lifetime, Gateway will be exposed to a variety of induced environments, including materials outgassing, chemical and electric thruster plumes, vacuum vents, and lunar dust transport (from the Human Lander System, HLS). Induced Environments can impact vehicle performance and mission success. The multidisciplinary Gateway Induced Environments Team has developed requirements and methodologies to address the complex challenge of integrating multiple elements and visiting vehicles while maintaining the Gateway induced environments within prescribed limits. The Gateway Induced Environments requirements are summarized along with the integration / verification process and preliminary system analysis results.

Gateway↗

NASA NTRSDate not supplied

Gateway Induced Environments Overview

Gateway↗

NASA NTRS1994

Collaborative engineering-design support system

Designing engineering objects requires many engineers' knowledge from different domains. There needs to be cooperative work among engineering designers to complete a design. Revisions of a design are time consuming, especially if designers work at a distance and with different design description formats. In order to reduce the design cycle, there needs to be a sharable design describing the engineering community, which can be electronically transportable. Design is a process of integrating that is not easy to define definitively. This paper presents Design Script which is a generic engineering design knowledge representation scheme that can be applied in any engineering domain. The Design Script is developed through encapsulation of common design activities and basic design components based on problem decomposition. It is implemented using CLIPS with a Windows NT graphical user interface. The physical relationships between engineering objects and their subparts can be constructed in a hierarchical manner. The same design process is repeatedly applied at each given level of hierarchy and recursively into lower levels of the hierarchy. Each class of the structure can be represented using the Design Script.

Lee, Dong HO↗

NASA NTRS2000

Web Exploration Tools for a Fast Federated Optical Survey Database

We implemented several new web-based tools to improve the efficiency and versatility of access to the APS Catalog of the POSS I (Palomar Observatory-National Geographic Sky Survey) and its associated image database. The most important addition was a federated database system to link the APS Catalog and image database into one Internet-accessible database. With the FDBS, the queries and transactions on the integrated database are performed as if it were a single database. We installed Myriad the FDBS developed by Professor Jaideep Srivastava and members of his group in the University of Minnesota Computer Science Department. It is the first system to provide schema integration, query processing and optimization, and transaction management capabilities in a single framework. The attached figure illustrates the Myriad architecture. The FDBS permits horizontal access to the data, not just vertical. For example, for the APS, queries can be made not only by sky position, but also by any parameter present in either of the databases. APS users will be able to produce an image of all the blue galaxies and stellar sources for comparison with x-ray source error ellipses from AXAF (X Ray Astrophysics Facility) (Chandra) for example. The FDBS is now available as a beta release with the appropriate query forms at our web site. While much of our time was occupied with adapting Myriad to the APS environment, we also made major changes in Star Base, our DBMS for the Catalog, at the web interface to improve its efficiency for issuing and processing queries. Star Base is now three times faster for large queries. Improvements were also made at the web end of the image database for faster access; although work still needs to be done to the image database itself for more efficient return with the FDBS. During the past few years, we made several improvements to the database pipeline that creates the individual plate databases queries by StarBase. The changes include improved positions especially for galaxies, using a new median centroider and integrated magnitudes for galaxies with an improved density-to-intensity calibration with a "sky" background subtraction. In the original version of StarBase the object classification fainter than 19.5-20.0 mag., was an extrapolation of the networks trained on brighter objects. We have used a new catalog of galaxies at the NGP to train a neural network on objects fainter than 20th mag. This improved classification is used in the new version of StarBase. We have also added a FITS table option for the returned data from queries on the object catalog. The APS image database includes images in both colors so we have added a tool for querying the image database in both colors simultaneously. The images can be displayed in parallel or blinked for comparison.

Humphreys, Roberta M.↗

NASA NTRS1988

The TAME Project: Towards improvement-oriented software environments

Experience from a dozen years of analyzing software engineering processes and products is summarized as a set of software engineering and measurement principles that argue for software engineering process models that integrate sound planning and analysis into the construction process. In the TAME (Tailoring A Measurement Environment) project at the University of Maryland, such an improvement-oriented software engineering process model was developed that uses the goal/question/metric paradigm to integrate the constructive and analytic aspects of software development. The model provides a mechanism for formalizing the characterization and planning tasks, controlling and improving projects based on quantitative analysis, learning in a deeper and more systematic way about the software process and product, and feeding the appropriate experience back into the current and future projects. The TAME system is an instantiation of the TAME software engineering process model as an ISEE (integrated software engineering environment). The first in a series of TAME system prototypes has been developed. An assessment of experience with this first limited prototype is presented including a reassessment of its initial architecture.

Basili, Victor R.↗

DOE OSTI2025

Sustainable Triacetic Acid Lactone Production from Sugarcane by Fermentation and Crystallization

Triacetic acid lactone (TAL) has the potential to serve as a bioderived platform chemical for commercial products including sorbic acid and recyclable polydiketoenamine plastics. In this study, we leveraged BioSTEAM to design, simulate, and evaluate (via techno-economic analysis, TEA, and life cycle assessment, LCA) TAL production from sugarcane. We experimentally characterized TAL solubility, calibrated solubility models, and designed a process to separate TAL from fermentation broths by crystallization. The biorefinery could produce TAL at a minimum product selling price (MPSP) of $\$3.73$–5.86·kg –1 (5th–95th percentiles; baseline at $\$4.60$·kg –1 ) and a carbon intensity (CI) of 5.31 [2.60–8.71] kg CO 2 -eq·kg –1 , which could enable financially viable, low-CI production of sorbic acid and polydiketoenamines. To drive down costs and CI, we explored the theoretical fermentation space (titer, yield, productivity combinations), operation scheduling and capacity expansion strategies (e.g., integrated sorghum processing), and potential separation improvements (mitigating TAL loss through pH control). Advancements in key design and technological parameters could further reduce MPSP by 51% to $\$2.26$·kg –1 [$\$1.97$–2.80·kg –1 ] and CI by 43% to 3.05 [1.91–4.15] kg CO 2 -eq·kg –1 . This research highlights the ability of agile TEA-LCA to screen promising designs, navigate sustainability trade-offs, prioritize research needs, and chart quantitative roadmaps to advance bioproducts and biofuels.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2023

Activation and Conversion of Methane to Syngas over ZrO 2 /Cu(111) Catalysts near Room Temperature

Enzymatic systems achieve the catalytic conversion of methane at room temperature under mild conditions. Here, in this study, varying thermodynamic and kinetic parameters, we show that the reforming of methane by water (MWR, CH 4 + H 2 O → CO + 3H 2 ) and the water-gas shift reaction (WGS, CO + H 2 O → H 2 + CO 2 ), two essential processes to integrate fossil fuels toward a H2 energy loop, can be achieved on ZrO 2 /Cu(111) catalysts near room temperature. Measurements of ambient-pressure X-ray photoelectron spectroscopy and mass spectrometry, combined with density functional calculations and kinetic Monte Carlo simulations, were used to study the behavior of the inverse oxide/metal catalysts. The superior performance is associated with a unique zirconia-copper interface, where multifunctional sites involving zirconium, oxygen, and copper work coordinatively to dissociate methane and water at 300 K and move forward the MWR and WGS processes.

03 NATURAL GAS↗

NASA NTRS2003

Cell output, cell cycle duration and neuronal specification: a model of integrated mechanisms of the neocortical proliferative process

The neurons of the neocortex are generated over a 6 day neuronogenetic interval that comprises 11 cell cycles. During these 11 cell cycles, the length of cell cycle increases and the proportion of cells that exits (Q) versus re-enters (P) the cell cycle changes systematically. At the same time, the fate of the neurons produced at each of the 11 cell cycles appears to be specified at least in terms of their laminar destination. As a first step towards determining the causal interrelationships of the proliferative process with the process of laminar specification, we present a two-pronged approach. This consists of (i) a mathematical model that integrates the output of the proliferative process with the laminar fate of the output and predicts the effects of induced changes in Q and P during the neuronogenetic interval on the developing and mature cortex and (ii) an experimental system that allows the manipulation of Q and P in vivo. Here we show that the predictions of the model and the results of the experiments agree. The results indicate that events affecting the output of the proliferative population affect both the number of neurons produced and their specification with regard to their laminar fate.

Evaluation Studies↗

DOE OSTI2025

Operation of Argonne's Liquid Salt-Liquid Metal Separation Testbed for U/TRU Product Processing

Argonne National Laboratory has constructed a liquid salt-liquid metal separation testbed for use in the development and advancement of cathode processing of U/TRU co‑deposits generated by pyroprocessing of used nuclear fuel. The U/TRU product recovered from the electrorefiner contains adhered and entrained salt that must be removed prior to consolidation of the U/TRU alloy for use in advanced reactor fuel fabrication. The bottom pour operation utilizes the low melting points of U/TRU co‑deposits and higher densities of molten metals compared to molten salts to separate and consolidate the U/TRU product. Argonne’s testbed is designed to support the development and optimization of bottom-pouring configurations for batch and semi-continuous operations, integration of process monitoring and control technologies, and determination of operational requirements for implementing in an industrial setting. Scoping tests were performed to demonstrate operational aspects of the testbed, including operation using single-pour spout and dual-pour spout configurations, effectiveness of salt containment and extent of salt vaporization, and the use of sensor probes to detect the location of the interface between the metal and salt phases during pouring. Recommendations for process optimization testing for further development of bottom pour processing to separate U/TRU alloys from adhered salt were made based on the results of scoping tests. Completing the recommended activities will increase the technical readiness level (TRL) of the liquid salt-liquid metal separation operation and consolidation of U/TRU alloys to support industrialization of pyroprocessing.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

NASA NTRS2011

Reusable Solid Rocket Motor - Accomplishments, Lessons, and a Culture of Success

The Reusable Solid Rocket Motor represents the largest solid rocket motor ever flown and the only human rated solid motor. Each Reusable Solid Rocket Motor (RSRM) provides approximately 3-million lb of thrust to lift the integrated Space Shuttle vehicle from the launch pad. The motors burn out approximately 2 minutes later, separate from the vehicle and are recovered and refurbished. The size of the motor and the need for high reliability were challenges. Thrust shaping, via shaping of the propellant grain, was needed to limit structural loads during ascent. The motor design evolved through several block upgrades to increase performance and to increase safety and reliability. A major redesign occurred after STS-51L with the Redesigned Solid Rocket Motor. Significant improvements in the joint sealing systems were added. Design improvements continued throughout the Program via block changes with a number of innovations including development of low temperature o-ring materials and incorporation of a unique carbon fiber rope thermal barrier material. Recovery of the motors and post flight inspection improved understanding of hardware performance, and led to key design improvements. Because of the multidecade program duration material obsolescence was addressed, and requalification of materials and vendors was sometimes needed. Thermal protection systems and ablatives were used to protect the motor cases and nozzle structures. Significant understanding of design and manufacturing features of the ablatives was developed during the program resulting in optimization of design features and processing parameters. The project advanced technology in eliminating ozone-depleting materials in manufacturing processes and the development of an asbestos-free case insulation. Manufacturing processes for the large motor components were unique and safety in the manufacturing environment was a special concern. Transportation and handling approaches were also needed for the large hardware segments. The reusable solid rocket motor achieved significant reliability via process control, ground test programs, and postflight assessment. Process control is mandatory for a solid rocket motor as an acceptance test of the delivered product is not feasible. Process control included process failure modes and effects analysis, statistical process control, witness panels, and process product integrity audits. Material controls and inspections were maintained throughout the sub tier vendors. Material fingerprinting was employed to assess any drift in delivered material properties. The RSRM maintained both full scale and sub-scale test articles. These enabled continuous improvement of design and evaluation of process control and material behavior. Additionally RSRM reliability was achieved through attention to detail in post flight assessment to observe any shift in performance. The postflight analysis and inspections provided invaluable reliability data as it enables observation of actual flight performance, most of which would not be available if the motors were not recovered. These unique challenges, features of the reusable solid rocket motor, materials and manufacturing issues, and design improvements will be discussed in the paper.

Moore, Dennis R.↗

DOE OSTI2024

Equitable Energy Metrics for Integration into Building Performance Standard Tracking Platforms: Preprint

Building Performance Standards (BPS) are being adopted globally and in the United States of America, where 14 different states and jurisdictions have a policy in place and many others are under development (Department of Energy (DOE) 2023). Accurate and equitable data sources are essential to make informed decisions about focusing investment on upgrading buildings to meet jurisdictional goals. There have been multiple new tools developed related to Energy Equity and Environmental Justice (EEEJ) and the resulting datasets need to be integrated into large building port-folios for quick access and better scalability. Integrating EEEJ data in a user-friendly format can help decision makers more quickly assess impacts and analyze the multitude of potentially significant metrics for which there is not yet consensus. In the U.S. and Canada, many BPS ordinances rely primarily on ENERGY STAR Portfolio Manager (ESPM) to capture building characteristics and energy and water consumption data. These datasets can then be imported into city-specific building tracking tools like the Standard Energy Efficiency Data Platform (SEED). Crucially, BPS decision makers require an efficient means of identifying buildings in priority communities to effectively allocate resources and funding. This process must integrate seamlessly with existing jurisdictional toolsets for optimal utility. This paper will demonstrate, for the case of Washington D.C.'s (the District) data, a workflow that provides actionable data for building upgrade investment prioritization in disadvantaged communities.

BPS↗

DOE OSTI2025

Life-Cycle Emissions and Human Health Implications of Multi-Input, Multi-Output Biorefineries

To meaningfully broaden the supply of fuels for the transportation sector, biofuel production must be scaled up and this requires a wider array of biomass feedstocks, including agricultural residues and organic waste. Rather than pursuing conversion of lignocellulosic biomass to fuels and anaerobic digestion of wastes as separate pathways, there are economic and environmental advantages associated with integrating these processes in a single facility. However, existing research rarely goes beyond carbon footprints in quantifying the effects of such a shift in bioenergy production. In addition to CO2, CH4, and N2O, this study explores the life-cycle air pollution (NH3, volatile organic compounds, NOx, SO2, and PM2.5), marine eutrophication, acidification, and local external cost implications of biorefineries capable of taking in crop residues, food waste, and manure to produce liquid fuel, electricity, and/or other options such as renewable natural gas (RNG), hydrogen, bioplastics, and protein-rich livestock feed. Relative to a single-input, single-output baseline, biorefineries integrated with organic waste codigestion to coproduce electricity or RNG can reduce life-cycle CO2-equivalent emissions by 84-149%, and the monetized external impacts across all scenarios range from $1.07/gallon to -$0.75/gallon ethanol.

Air pollution↗

DOE OSTI2024

Optimization strategies for produced water networks with integrated desalination facilities

Optimal management and desalination of produced water is a major challenge for U.S. oil and gas development. Integrating rigorous desalination models into multi-period produced water network optimization problems presents several hurdles, which need to be tackled using advanced optimization strategies. Here, in this work, a novel multi-period produced water network formulation with separate solid and liquid flows is introduced to avoid singularities at zero flows. Rigorous steady state desalination models based on mechanical vapor recompression are embedded at the desalination sites in the network model. An integrated optimization formulation is developed to co-optimize the design of desalination units along with the operation of the network. Furthermore, a more robust approach based on the trust region filter method is developed to efficiently integrate complex desalination models into the multi-period planning problem. Both optimization approaches are demonstrated on a produced water network from the PARETO library (Drouven et al., 2022) using thermal desalination units. Our results show that while the TRF and integrated approaches have comparable solve times, the TRF approach has better performance reliability in terms of solver convergence. Furthermore, the optimal solution obtained by embedding rigorous models into the network is significantly different than when desalination costs are approximated using simple cost models, which motivates further research in this field.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2025

Chloride Molten Salt Electrolysis Enables Integrated and Energy-Efficient Process for NdFeB Magnet Fabrication

Rare-earth elements (REEs) have been identified by NATO, the USDOE, and USGS as critical materials, i.e., materials which have significant demand yet pose supply-chain risks. Many of the existing processes for separations, metallization, and final parts production used across the REE supply chain involve energy intensive steps. For example, neodymium (Nd or NdPr) is produced using oxyfluoride electrolysis of Nd 2 O 3 , which requires hydrofluoric acid to produce a key electrolyte component (NdF 3 ) and generates undesired perfluorocarbon (PFC) gases. Such challenges make securing a resilient supply chain for NdFeB permanent magnets in countries like the United States prohibitively difficult. Here, we propose a chloride-based MSE process that circumvents these challenges, delivering high-purity NdPr from a (NdPr)Cl 3 feed from upstream REE separations. This eliminates environmentally-damaging steps of oxalate or carbonate precipitation and calcination, and enables superior production rates due to greater solubility of (NdPr)Cl 3 in chloride melts compared to Nd 2 O 3 . We show that CMSE generates high-purity NdPr (99.4 wt.%) while being energy-efficient (~ 6 kWh/kg-Nd). NdPr from CMSE was used to fabricate a NdFeB magnet with an excellent maximum energy product (> 40 MGOe), comparable to commercially available NdFeB magnets. This establishes CMSE as a leading approach for integrated, energy-efficient NdFeB magnet production.

Materials science↗

NASA NTRS2018

Lessons for WFIRST CGI from Ground-Based High-Contrast Systems

The Coronagraph Instrument (CGI) for NASA’s Wide Field Infrared Survey Telescope (WFIRST) will constitute a dramatic step forward for high-contrast imaging, integral ﬁeld spectroscopy, and polarimetry of exoplanets and circumstellar disks, aiming to improve upon the sensitivity of current ground-based direct imaging facilities by 2–3 orders of magnitude. Furthermore, CGI will serve as a pathﬁnder for future exo-Earth imaging and characterization missions by demonstrating wavefront control, coronagraphy, and spectral retrieval in a new contrast regime, and by validating instrument and telescope models at unprecedented levels of precision. To achieve this jump in performance, it is critical to draw on the experience of ground-based high-contrast facilities. We discuss several areas of relevant commonalities, including: wavefront control, post-processing of integral ﬁeld unit data, and calibration and observing strategies.

Xuan, Wenhao↗

NASA NTRSDate not supplied

Lunar Science and Mission Systems Integration for Real-Time Long Duration Remote Robot Surface Operations

Conducting lunar science with a robot on the Moon that is commanded in real-time from Earth by distributed workgroups for long durations is a specific activity that has been developed by many projects including NASA’s Volatiles Investigating Polar Exploration Rover (VIPER) mission. VIPER’s nominal mission period for surface operations was set for 100 Earth days (four lunar days). VIPER’s science knowledge acquisition was set to focus on characterizing the distribution of water and volatiles across a range of thermal environments, within a traverse planned to optimize science return across up to 20 km. While VIPER’s status is the subject of discussion, there is research and analysis from the development and simulations phases that are of benefit to the lunar science community and future remote science operations projects. Discussed here are some findings on the process of integrating lunar science with mission system operations.

VIPER↗

NASA NTRS2016

Aerosol-Radiation-Cloud Interactions in the South-East Atlantic: First Results from the ORACLES-2016 Deployment and Plans for Future Activities

Southern Africa produces almost a third of the Earths biomass burning (BB) aerosol particles. Particles lofted into the mid-troposphere are transported westward over the South-East (SE) Atlantic, home to one of the three permanent subtropical stratocumulus (Sc) cloud decks in the world. The SE Atlantic stratocumulus deck interacts with the dense layers of BB aerosols that initially overlay the cloud deck, but later subside and may mix into the clouds. These interactions include adjustments to aerosol-induced solar heating and microphysical effects, and their global representation in climate models remains one of the largest uncertainties in estimates of future climate. Hence, new observations over the SE Atlantic have significant implications for regional and global climate change predictions.Our understanding of aerosol-cloud interactions in the SE Atlantic is severely limited. Most notably, we are missing knowledge on the absorptive and cloud nucleating properties of aerosols, including their vertical distribution relative to clouds, on the locations and degree of aerosol mixing into clouds, on the processes that govern cloud property adjustments, and on the importance of aerosol effects on clouds relative to co-varying synoptic scale meteorology.We describe first results from various synergistic, international research activities aimed at studying aerosol-cloud interactions in the region:NASAs airborne ORACLES (ObseRvations of Aerosols Above Clouds and Their IntEractionS) deployment in AugustSeptember of 2016,the DoEs LASIC (Layered Atlantic Smoke Interactions with Clouds) deployment of the ARM Mobile Facility to Ascension Island (June 2016 October 2017), the ground-based components of CNRS AEROCLO-sA (Aerosols Clouds and Fog over the west coast of southern Africa), and ongoing regional-scale integrative, process-oriented science efforts as part of SEALS-sA (Sea Earth Atmosphere Linkages Study in southern Africa).We expect to describe experimental setups as well as showcase initial aerosol and cloud property distributions. Furthermore, we discuss the implementation of future activities in these programs in coordination with the UK Met Offices CLARIFY (CLoud-Aerosol-Radiation Interactions and Forcing) experiment in 2017.

aerosol↗